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HITL Test Infrastructure Engineer
Castelion · Allen, Texas, United States
Pay
$105k–225k
Setting
On-site
HITL Test Infrastructure Engineer
Allen, Texas, United States
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Job Openings HITL Test Infrastructure Engineer
About the job HITL Test Infrastructure Engineer
Why Castelion, Why Now
Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.
This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.
HITL Test Infrastructure Engineer
As a HITL Test Infrastructure Engineer, you will architect, develop, and own Castelion's Hardware-in-the-Loop (HITL) test infrastructure used to verify embedded software and firmware running on flight-critical hardware. Your systems will enable developers and automated CI/CD pipelines to reserve physical hardware, deploy software and firmware, execute automated tests, and rapidly validate system performance using production-representative hardware.
You'll work across software, firmware, avionics, FPGA, electrical, and systems engineering teams to build scalable, resilient, and highly automated test environments supporting microcontrollers, FPGAs, GPUs, and custom electronics. Your work will significantly improve development velocity and software quality by providing engineers with fast, reliable feedback before hardware reaches the vehicle.
At Castelion, engineers own their systems from concept through production. You'll design infrastructure that is robust, maintainable, intuitive to use, and capable of scaling alongside our rapidly growing engineering organization.
Responsibilities
Design, develop, and own Castelion's Hardware-in-the-Loop (HITL) test infrastructure for embedded software and firmware verification.
Build scalable HITL test stations capable of supporting microcontrollers, FPGAs, GPUs, and custom compute hardware with specialized power and interface requirements.
Develop automated test frameworks that verify software loading, boot sequences, runtime performance, functional behavior, and system requirements.
Integrate HITL systems into Kubernetes and CI/CD workflows, enabling developers and automated verification pipelines to reserve hardware, flash devices, execute tests, and review results.
Develop Python-based test software, automation tools, and infrastructure to maximize test coverage and engineering productivity.
Design automated test execution strategies for code commits, pull requests, nightly builds, release candidates, and other development milestones.
Build reliable hardware reservation, scheduling, and resource management capabilities that maximize lab utilization.
Partner closely with software, firmware, FPGA, avionics, electrical, and systems engineers to define verification requirements and expand automated test coverage.
Debug complex issues spanning hardware, firmware, software, networking, and infrastructure.
Continuously improve the reliability, scalability, uptime, automation, and user experience of Castelion's HITL infrastructure.
Support board bring-up, hardware integration, lab automation, and prototype testing activities as new hardware platforms are introduced.
Establish best practices for automated verification, hardware management, and continuous integration across engineering teams.
Basic Qualifications
Bachelor's degree in Computer Engineering, Electrical Engineering, Computer Science, Software Engineering, or a related technical discipline, or equivalent practical experience.
Experience developing software using Python.
Experience building automated test frameworks using tools such as pytest, Robot Framework, or similar.
Familiarity with embedded software and firmware development workflows, including flashing, booting, debugging, and runtime validation.
Experience working with serial, JTAG, SWD, or similar hardware debug interfaces.
Basic understanding of embedded hardware and the ability to read electrical schematics.
Experience working in Linux development environments.
Basic understanding of Kubernetes, containerized infrastructure, or modern CI/CD systems.
Ability to troubleshoot issues across hardware, firmware, software, and infrastructure boundaries.
Comfortable working in a laboratory environment with custom electronics, instrumentation, power supplies, and prototype hardware.
Preferred Skills and Experience
Experience developing Hardware-in-the-Loop (HITL) or automated hardware test systems.
Experience integrating hardware validation into CI/CD pipelines.
Experience with microcontrollers, FPGAs, GPUs, SoCs, or custom embedded compute platforms.
Experience with board bring-up, lab automation, instrument control, power sequencing, or custom power delivery systems.
Familiarity with FPGA development workflows, including VHDL, Verilog, or SystemVerilog.
Experience reading FPGA code to understand interfaces, expected behavior, and verification requirements.
Experience with Git-based software development workflows.
Experience building hardware reservation, orchestration, or resource scheduling systems.
Experience with networking, distributed systems, or Kubernetes-based infrastructure.
Experience developing scalable engineering infrastructure supporting multiple development teams.
Other Duties
Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Benefits And Perks
All full-time employees are granted meaningful long-term equity, sharing in the company's significant growth trajectory. We offer four (4) weeks of paid time off, ten (10) company-paid holidays, and comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage, along with dental and vision plans. We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience. In addition, employees enjoy perks like catered meals, company-covered food during high-demand periods, and a fully stocked kitchen to stay fueled throughout the day.
While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.
Affirmative Action/EEO Statement
Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
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Listed by Castelion for a position based in the United States. Employers on this board attest they are hiring domestically.
Manufacturing Engineer, Propellant
Castelion · Midland, Texas, United States
Pay
$95k–160k
Setting
On-site
Manufacturing Engineer, Propellant
Midland, Texas, United States
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Or refer someone
Job Openings Manufacturing Engineer, Propellant
About the job Manufacturing Engineer, Propellant
Why Castelion, Why Now
Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.
This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.
Manufacturing Engineer, Propellant
We are seeking a Propellant Manufacturing Engineer to lead and execute propellant manufacturing processes for solid rocket motors (SRM) supporting Castelion's hypersonic strike programs, including Blackbeard. This role focuses on the development, optimization, qualification, and scaling of propellant formulation, mixing, casting, curing, and related processes. You will work hands-on with energetic materials in a high-consequence environment, driving process reliability, yield, safety, and throughput as we transition from prototype and research builds to high-rate production. Partnering closely with Propulsion Design, Manufacturing, Quality, Automation & Controls, and Test teams, you will ensure propellant processes meet stringent performance, safety, and producibility requirements.
Responsibilities
Own or lead propellant manufacturing processes, including ingredient preparation, batch mixing, vacuum casting, grain forming, curing, and finishing operations.
Develop, document, and continuously improve process parameters, work instructions, and control plans for propellant production.
Execute Design for Manufacturability (DFM) and process FMEA activities; drive statistical process control (SPC) and yield improvement initiatives.
Support new product introduction (NPI) by translating propellant formulation and grain design requirements into robust, scalable manufacturing processes.
Perform root-cause analysis and implement corrective/preventive actions for process deviations, defects, or quality issues. Collaborate with Automation & Controls teams to introduce or improve mixing, casting, and handling automation while maintaining strict safety and process control.
Ensure full compliance with energetic materials handling protocols, DoD 4145.26-M, ATF regulations, ITAR, and site-specific explosive safety standards.
Support equipment selection, qualification, maintenance, and process validation for mixers, casting systems, ovens, and related tooling.
Interface with suppliers on propellant ingredients and intermediate materials; contribute to incoming quality and supplier process improvements.
Mentor junior engineers and technicians; contribute to training programs and process standardization across production sites.
Support facility ramp and capability expansion at the Midland, TX operations and Project Ranger campus in New Mexico.
Basic Qualifications
Bachelor's or Master's degree in Chemical Engineering, Materials Science, Manufacturing Engineering, Mechanical Engineering, or related technical field.
5+ years of manufacturing or process engineering experience, with at least 3+ years hands-on work involving solid propellants, energetic materials, or analogous high-hazard chemical/process manufacturing.
Demonstrated experience developing or scaling mixing, casting, or similar batch/process operations in a regulated environment.
Hands-on experience with propellant or energetic mixing (planetary, vertical, or similar mixers), vacuum casting, and curing processes.
Strong understanding of propellant rheology, ingredient interactions, process sensitivity, and quality attributes (density, voids, mechanical properties, ballistic performance).
Proficiency with process documentation, statistical tools (Minitab or similar), PFMEA, and root-cause methodologies.
Familiarity with process equipment design/qualification, instrumentation, and data collection for batch processes.
Working knowledge of energetic materials safety, hazardous location requirements, and large-scale chemical handling practices.
Ability to interpret engineering drawings, specifications, and material data sheets.
Preferred Skills and Experience
Direct experience manufacturing solid rocket motor propellants for DoD, NASA, or commercial space/hypersonic programs.
Background in fast-paced aerospace or defense production environments (startups or primes).
Experience scaling processes from laboratory/prototype to low-rate or high-rate production.
Familiarity with insensitive munitions practices, motor case interfaces, or propellant-to-liner bonding processes.
Prior involvement in facility stand-up, equipment commissioning, or production ramp of energetic materials lines.
Experience with ITAR-controlled programs and classified manufacturing environments.
Other Duties
Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Benefits And Perks
All full-time employees are granted meaningful long-term equity, sharing in the company's significant growth trajectory. We offer four (4) weeks of paid time off, ten (10) company-paid holidays, and comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage, along with dental and vision plans. We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience. In addition, employees enjoy perks like catered meals, company-covered food during high-demand periods, and a fully stocked kitchen to stay fueled throughout the day.
While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.
Affirmative Action/EEO Statement
Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
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Or refer someone
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Listed by Castelion for a position based in the United States. Employers on this board attest they are hiring domestically.
Site Operations Manager
Castelion · Midland, Texas, United States
Pay
$75k–130k
Setting
On-site
Site Operations Manager
Midland, Texas, United States
Apply for Position
Or refer someone
Job Openings Site Operations Manager
About the job Site Operations Manager
Why Castelion, Why Now
Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.
This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.
Site Operations Manager
We are seeking a Site Operations Manager to own end-to-end operations of Castelion's R&D manufacturing and testing site for solid rocket motors (SRMs). This leadership role is responsible for the safe, efficient, and high-quality execution of propellant manufacturing, motor assembly, and testing activities supporting prototype, development, and early production hardware for hypersonic programs including Blackbeard. You will lead a multidisciplinary team of engineers, technicians, and operators; drive operational excellence across manufacturing and test; and ensure the site delivers on aggressive development schedules while maintaining the highest standards of energetic materials safety, quality, and compliance. This position serves as the primary operational leader for the development site and partners closely with Propulsion Design, Manufacturing Engineering, Test Engineering, Quality, and Program Management.
Responsibilities
Own day-to-day operations of the development site, including propellant manufacturing (mixing, casting, curing), SRM assembly/integration, and testing (static fire, environmental, functional, and related development tests).
Lead, mentor, and develop a high-performing team of manufacturing engineers, test engineers, technicians, and operators; foster a strong safety culture and continuous improvement mindset.
Develop and execute site operational plans, schedules, and resource allocation to meet program milestones for R&D builds and testing campaigns.
Drive process maturity, yield improvement, throughput, and cost efficiency while transitioning processes from R&D/prototype to more repeatable production-ready methods.
Ensure rigorous compliance with energetic materials handling, DoD 4145.26-M, ATF regulations, ITAR, range safety, and all site-specific explosive safety and environmental standards.
Oversee facility readiness, equipment uptime, maintenance coordination, and capital planning for mixers, casting systems, test stands, instrumentation, and support infrastructure.
Partner with Test Engineering and Propulsion teams to plan, resource, and execute safe and effective static fire and other development tests; support post-test data reviews and anomaly resolution.
Collaborate cross-functionally with Design, Manufacturing Engineering, Quality, Supply Chain, and Automation teams on new product introduction, process changes, and design-for-manufacturability/testability feedback.
Lead root-cause investigations, corrective actions, and continuous improvement initiatives across manufacturing and test operations.
Support capability expansion and knowledge transfer as processes scale to higher-rate production sites (including Project Ranger in New Mexico).
Basic Qualifications
Bachelor's degree in Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Manufacturing Engineering, Industrial Engineering, or related technical field.
10+ years of progressive experience in manufacturing, operations, or test leadership within aerospace, defense, propulsion, or energetic materials environments.
5+ years in a supervisory or management role leading teams responsible for production, R&D manufacturing, or testing operations.
Demonstrated experience owning or significantly contributing to solid rocket motor, propellant, or analogous high-hazard manufacturing and testing operations.
Working knowledge of solid rocket motor manufacturing processes (propellant mixing/casting, composite case integration, assembly) and development testing (static fire, instrumentation, data acquisition).
Familiarity with facility and equipment management for energetic materials operations, including safety systems and hazardous process controls.
Ability to interpret engineering drawings, process specifications, test plans, and quality requirements.
Working knowledge of ERP/MES systems, configuration management, and production control practices.
Preferred Skills and Experience
Direct leadership experience in solid rocket motor or missile propulsion R&D manufacturing and testing environments.
Background in fast-paced aerospace or defense organizations (startups or primes) with aggressive development timelines.
Experience standing up or scaling new manufacturing/test capabilities or facilities.
Prior responsibility for energetic materials safety programs, ATF compliance, or range safety interfaces.
Familiarity with ITAR-controlled programs and classified operations.
Experience supporting transition of processes from development site to higher-rate production facilities.
Other Duties
Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Benefits And Perks
All full-time employees are granted meaningful long-term equity, sharing in the company's significant growth trajectory. We offer four (4) weeks of paid time off, ten (10) company-paid holidays, and comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage, along with dental and vision plans. We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience. In addition, employees enjoy perks like catered meals, company-covered food during high-demand periods, and a fully stocked kitchen to stay fueled throughout the day.
While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.
Affirmative Action/EEO Statement
Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
Apply for Position
Or refer someone
Share
Powered by Manatal
Listed by Castelion for a position based in the United States. Employers on this board attest they are hiring domestically.
Site Operations Manager
Castelion · Midland, Texas, United States
Pay
$75k–130k
Setting
On-site
Site Operations Manager
Midland, Texas, United States
Apply for Position
Or refer someone
Job Openings Site Operations Manager
About the job Site Operations Manager
Why Castelion, Why Now
Castelion is moving incredibly fast to develop and deliver advanced defense systems at a time when execution matters more than ever. We believe focus and technical excellence are decisive advantages - and we are building a team that can deliver real capability, not just concepts.
This is a rare opportunity to join at an early stage, where your work will directly shape critical systems, influence major technical decisions, and have immediate, real-world impact.
Site Operations Manager
We are seeking a Site Operations Manager to own end-to-end operations of Castelion's R&D manufacturing and testing site for solid rocket motors (SRMs). This leadership role is responsible for the safe, efficient, and high-quality execution of propellant manufacturing, motor assembly, and testing activities supporting prototype, development, and early production hardware for hypersonic programs including Blackbeard. You will lead a multidisciplinary team of engineers, technicians, and operators; drive operational excellence across manufacturing and test; and ensure the site delivers on aggressive development schedules while maintaining the highest standards of energetic materials safety, quality, and compliance. This position serves as the primary operational leader for the development site and partners closely with Propulsion Design, Manufacturing Engineering, Test Engineering, Quality, and Program Management.
Responsibilities
Own day-to-day operations of the development site, including propellant manufacturing (mixing, casting, curing), SRM assembly/integration, and testing (static fire, environmental, functional, and related development tests).
Lead, mentor, and develop a high-performing team of manufacturing engineers, test engineers, technicians, and operators; foster a strong safety culture and continuous improvement mindset.
Develop and execute site operational plans, schedules, and resource allocation to meet program milestones for R&D builds and testing campaigns.
Drive process maturity, yield improvement, throughput, and cost efficiency while transitioning processes from R&D/prototype to more repeatable production-ready methods.
Ensure rigorous compliance with energetic materials handling, DoD 4145.26-M, ATF regulations, ITAR, range safety, and all site-specific explosive safety and environmental standards.
Oversee facility readiness, equipment uptime, maintenance coordination, and capital planning for mixers, casting systems, test stands, instrumentation, and support infrastructure.
Partner with Test Engineering and Propulsion teams to plan, resource, and execute safe and effective static fire and other development tests; support post-test data reviews and anomaly resolution.
Collaborate cross-functionally with Design, Manufacturing Engineering, Quality, Supply Chain, and Automation teams on new product introduction, process changes, and design-for-manufacturability/testability feedback.
Lead root-cause investigations, corrective actions, and continuous improvement initiatives across manufacturing and test operations.
Support capability expansion and knowledge transfer as processes scale to higher-rate production sites (including Project Ranger in New Mexico).
Basic Qualifications
Bachelor's degree in Mechanical Engineering, Chemical Engineering, Aerospace Engineering, Manufacturing Engineering, Industrial Engineering, or related technical field.
10+ years of progressive experience in manufacturing, operations, or test leadership within aerospace, defense, propulsion, or energetic materials environments.
5+ years in a supervisory or management role leading teams responsible for production, R&D manufacturing, or testing operations.
Demonstrated experience owning or significantly contributing to solid rocket motor, propellant, or analogous high-hazard manufacturing and testing operations.
Working knowledge of solid rocket motor manufacturing processes (propellant mixing/casting, composite case integration, assembly) and development testing (static fire, instrumentation, data acquisition).
Familiarity with facility and equipment management for energetic materials operations, including safety systems and hazardous process controls.
Ability to interpret engineering drawings, process specifications, test plans, and quality requirements.
Working knowledge of ERP/MES systems, configuration management, and production control practices.
Preferred Skills and Experience
Direct leadership experience in solid rocket motor or missile propulsion R&D manufacturing and testing environments.
Background in fast-paced aerospace or defense organizations (startups or primes) with aggressive development timelines.
Experience standing up or scaling new manufacturing/test capabilities or facilities.
Prior responsibility for energetic materials safety programs, ATF compliance, or range safety interfaces.
Familiarity with ITAR-controlled programs and classified operations.
Experience supporting transition of processes from development site to higher-rate production facilities.
Other Duties
Please note this job description is not designed to cover or contain a comprehensive listing of activities, duties or responsibilities that are required of the employee for this job. Duties, responsibilities and activities may change at any time with or without notice.
Benefits And Perks
All full-time employees are granted meaningful long-term equity, sharing in the company's significant growth trajectory. We offer four (4) weeks of paid time off, ten (10) company-paid holidays, and comprehensive health benefits - including 100% employee-covered medical and strong dependent coverage, along with dental and vision plans. We also provide paid parental leave to support growing families, a $100 monthly fitness stipend to promote health and performance, and onsite EV charging for convenience. In addition, employees enjoy perks like catered meals, company-covered food during high-demand periods, and a fully stocked kitchen to stay fueled throughout the day.
While this position does not currently require a U.S government-issued security clearance, it may in the near future. Therefore, the ability to obtain and maintain a U.S. government–issued security clearance is required. U.S. citizenship is required, as only U.S. citizens are eligible for a security clearance.
Affirmative Action/EEO Statement
Employment with Castelion is governed on the basis of competence and qualifications and will not be influenced in any manner by race, color, religion, gender, national origin/ethnicity, veteran status, disability status, age, sexual orientation, gender identity, marital status, mental or physical disability or any other legally protected status.
Apply for Position
Or refer someone
Share
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Listed by Castelion for a position based in the United States. Employers on this board attest they are hiring domestically.
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